impact-echo scanning for grout void detection in post

15
1 Impact-Echo Scanning for Grout Void Detection in Post-tensioned Bridge Ducts - Findings from a Research Project and a Case History (presented at ASCE Structures Congress, Long Beach, California, May 2007) Authors: Yajai Tinkey, Ph.D., Olson Engineering, Inc., 12401 W. 49 th Ave. Wheat Ridge, CO 80033, USA, [email protected] Larry D. Olson, P.E., Olson Engineering, Inc., 12401 W. 49 th Ave. Wheat Ridge, CO 80033, USA, [email protected] ABSTRACT This paper presents the findings from a research project funded by the National Cooperative Highway Research Program-Innovations Deserving Exploratory Analysis (NCHRP – IDEA) Program. Experimental results are presented herein from the research studies which involved a defect sensitivity study of an Impact-Echo (IE) Scanner to detect and image discontinuities in post-tensioned ducts of a mockup U-shaped bridge girder and a mockup slab. Different sizes of ducts were included in this study as well as varying sizes of void defects. Detailed sensitivity study of non-destructive grout defect detection with Impact-Echo Scanning of 8-four inch diameter ducts with constructed defects was the main focus in this study. Comparisons of the IE defect interpretation and the actual design conditions of the ducts inside the bridge girder/slab are presented. The IE results are presented in a three-dimensional fashion using thickness surface plots to provide improved visualization and interpretation of the internal grout to void defect conditions inside the ducts of the girder. The Impact-Echo tests were performed with a Scanner which greatly facilitates the Impact-Echo test process by allowing for rapid, near continuous testing and true “scanning” capabilities to test concrete structures. The paper summarizes the general background of the Impact-Echo technique and the Impact-Echo Scanner. Descriptions of two mock-up specimens used in the experiment and the discussion of the results from the Impact-Echo Scanner are presented herein. Finally, a case study using an Impact Echo Scanner to locate grout voids inside the Orwell Bridge in UK is included in this paper. INTRODUCTION Post-tensioned systems have been widely used for infrastructure bridge transportation systems since late 1950s. However if a good quality control plan is not implemented during construction, there is the potential problem during construction that the duct may not be fully grouted. This results in voids in some areas or inefficient protection for prestressing steel. Over the long term, water can enter the tendon ducts in the void areas resulting in corrosion of the tendon. The collapse of the Brickton Meadows Footbridge in Hampshire (UK) in 1967 is the first serious case of corrosion of tendons leading to major catastrophe (1). In 1985, the collapse of a precast segmental, post-tensioned bridge in Wales (Ynys-y-Gwas Bridge) was attributed to corrosion of the internal prestressing tendons at mortar joints between segments (1 and 2). Corrosion-related failures of post-tensioning tendons have been found in several major segmental bridges such as the Niles Channel Bridge near Key West, FL in 1999 and Midway Bridge near Destin, FL in

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Page 1: Impact-Echo Scanning for Grout Void Detection in Post

1

Impact-Echo Scanning for Grout Void Detection in Post-tensioned

Bridge Ducts - Findings from a Research Project and a Case History (presented at ASCE Structures Congress, Long Beach, California, May 2007)

Authors:

Yajai Tinkey, Ph.D., Olson Engineering, Inc., 12401 W. 49th

Ave. Wheat Ridge, CO 80033,

USA, [email protected]

Larry D. Olson, P.E., Olson Engineering, Inc., 12401 W. 49th

Ave. Wheat Ridge, CO 80033,

USA, [email protected]

ABSTRACT

This paper presents the findings from a research project funded by the National Cooperative

Highway Research Program-Innovations Deserving Exploratory Analysis (NCHRP – IDEA)

Program. Experimental results are presented herein from the research studies which involved a

defect sensitivity study of an Impact-Echo (IE) Scanner to detect and image discontinuities in

post-tensioned ducts of a mockup U-shaped bridge girder and a mockup slab. Different sizes of

ducts were included in this study as well as varying sizes of void defects. Detailed sensitivity

study of non-destructive grout defect detection with Impact-Echo Scanning of 8-four inch

diameter ducts with constructed defects was the main focus in this study. Comparisons of the IE

defect interpretation and the actual design conditions of the ducts inside the bridge girder/slab are

presented. The IE results are presented in a three-dimensional fashion using thickness surface

plots to provide improved visualization and interpretation of the internal grout to void defect

conditions inside the ducts of the girder. The Impact-Echo tests were performed with a Scanner

which greatly facilitates the Impact-Echo test process by allowing for rapid, near continuous

testing and true “scanning” capabilities to test concrete structures. The paper summarizes the

general background of the Impact-Echo technique and the Impact-Echo Scanner. Descriptions

of two mock-up specimens used in the experiment and the discussion of the results from the

Impact-Echo Scanner are presented herein. Finally, a case study using an Impact Echo Scanner

to locate grout voids inside the Orwell Bridge in UK is included in this paper.

INTRODUCTION

Post-tensioned systems have been widely used for infrastructure bridge transportation systems

since late 1950s. However if a good quality control plan is not implemented during construction,

there is the potential problem during construction that the duct may not be fully grouted. This

results in voids in some areas or inefficient protection for prestressing steel. Over the long term,

water can enter the tendon ducts in the void areas resulting in corrosion of the tendon. The

collapse of the Brickton Meadows Footbridge in Hampshire (UK) in 1967 is the first serious case

of corrosion of tendons leading to major catastrophe (1). In 1985, the collapse of a precast

segmental, post-tensioned bridge in Wales (Ynys-y-Gwas Bridge) was attributed to corrosion of

the internal prestressing tendons at mortar joints between segments (1 and 2). Corrosion-related

failures of post-tensioning tendons have been found in several major segmental bridges such as

the Niles Channel Bridge near Key West, FL in 1999 and Midway Bridge near Destin, FL in

Page 2: Impact-Echo Scanning for Grout Void Detection in Post

2

2000 (3). In addition to actual failures, corrosion damage was found in many post-tensioned

bridge ducts in bridges still in use in Florida and East Coast areas (4).

In post-tensioned structures, quantifying the incidence of corrosion is further complicated by

limitations in techniques for detecting corrosion. Condition surveys of post-tensioned structures

are often limited to visual inspections for signs of cracking, spalling and rust stain. This limited

technique may overlook corrosion activity. Corrosion damage in post-tensioned elements has

been found in situation where no exterior indications of distress were apparent (4). As a matter

of fact, the Ynys-y-Gwas Bridge in Wales had been inspected 6 months prior to the collapse, and

no apparent signs of distress were observed (2). Examples such as this one lead some to fear

that inspection based on limited exploratory or visual inspections may be unconservative and

may produce a false sense of security. The X-ray method is the oldest technique applied

successfully to detect unfilled ducts. However, the method suffers from many disadvantages.

The first disadvantage is that the X-Ray test needs accesses to both sides of the structure, which

is not usually practical in testing bridge ducts. Second, the inspection areas are relatively small

and the test time relatively large resulting a slow testing process. Finally, the need for sufficient

radiation protection and personnel evacuation is usually a problem. Therefore, it is important to

develop a reliable method to practically inspect the quality of grout fill inside the ducts non-

destructively after the grouting process is complete and for inspection of older bridges.

BACKGROUND OF THE IMPACT ECHO TECHNIQUE

The Impact-Echo test involves dynamically exciting a concrete structure with a small mechanical

impactor and measuring the reflected wave energy with a displacement transducer. The

resonant echoes in the displacement responses are usually not apparent in the time domain, but

are more easily identified in the frequency domain. Consequently, linear amplitude spectra of

the displacement responses are calculated by performing a Fast Fourier Transform (FFT)

analysis to determine the resonant echo peak frequencies in the frequency domain from the

displacement transducer signals in the time domain. The relationship among the echo frequency

peak f, the compression wave velocity VP, and the echo depth D is expressed in the following

equation:

(1) D = βVp/(2*f)

where β is a shape factor which varies based on geometry. The value of β was found by

theoretical modeling to be equal to 0.96 for a slab/wall shape (5).

Impact-Echo Scanner

The Impact-Echo rolling Scanner was first conceived by the second author of this paper and

subsequently researched and developed as a part of a US Bureau of Reclamation prestressed

concrete cylinder pipe integrity research project (6). This technique is based on the Impact-Echo

method (5 and 7). In general, the purpose of the Impact-Echo test is usually to either locate

delaminations, honeycombing or cracks parallel to the surface or to measure the thickness of

concrete structures with typically one-sided access for testing (pavements, floors, retaining walls,

Page 3: Impact-Echo Scanning for Grout Void Detection in Post

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tunnel linings, buried pipes, etc.). To expedite the Impact-Echo testing process, an Impact-Echo

scanning device has been developed with a rolling transducer assembly incorporating multiple

sensors, attached underneath the test unit. When the test unit is rolled across the testing surface,

an opto-coupler on the central wheel keeps track of the distance. This unit is calibrated to impact

and record data at intervals of nominally 25 mm (1 inch). If the concrete surface is smooth, a

coupling agent between the rolling transducer and test specimen is not required. However, if the

concrete surface is somewhat rough, water can be used as a couplant to attempt to improve

displacement transducer contact conditions. The maximum frequency of excitation of the

impactor in the scanner used in research is 25 kHz. The impactor in scanner can be replaced for

an impactor that generates higher frequency. A comparison of the Impact-Echo Scanner and the

point by point Impact-Echo Scanner unit is shown in Figure 1. Typical scanning time for a line

of 4 m (13 ft), approximately 160 test points, is 60 seconds. In an Impact-Echo scanning line,

the resolution of the scanning is about 25 mm (1 inch) between IE test points. Data analysis and

visualization was achieved using Impact-Echo scanning software developed by the first author

for this research project. Raw data in the frequency domain were first digitally filtered using a

Butterworth filter with a band-pass range of 2 kHz to 20 kHz. Due to some rolling noise

generated by the Impact-Echo Scanner, a band-stop filter was also used to remove undesired

rolling noise frequency energy. Automatic and manual picks of dominant frequency were

performed on each spectrum and an Impact-Echo thickness was calculated based on the selected

dominant frequency. A three-dimensional plot of the condition of the tested specimens was

generated by combining the calculated Impact-Echo thicknesses from each scanning line. The

three-dimensional results can be presented in either color or grayscale.

FIGURE 1 – IMPACT-ECHO SCANNER UNIT AND POINT-BY-POINT IMPACT-ECHO UNIT

GENERAL DESCRIPTION OF THE SPECIMENS AND DEFECTS

The specimen used in this study is a full scale pre-cast girder with eight steel ducts inside.

Construction of the modified Styrofoam defects for the mockup girder is described in this section

as well.

Description of the Mockup Girder and Constructions of Grout Defects

A full scale pre-cast bridge girder (U-shaped) was donated to the research team by EnCon Bridge

Company (Denver, Colorado) for use in grout defect sensitivity studies. The length of the girder

is 30.48 m (100 ft) with a typical wall thickness of 254 mm (10 in). There were four empty

Impact-Echo Scanner

Point-by-point IE-1 Impact-Echo Unit

tube to provide

water for coupling

tube to provide water for coupling

Rolling transducer Displacement transducer

automatic impactors

wheels

Page 4: Impact-Echo Scanning for Grout Void Detection in Post

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metal ducts (101.6 mm or 4 inches in diameter) inside each wall (Figure 2). The west end of the

girder (6.1 m or 20 ft long) was selected for this study.

FIGURE 2 – U-SHAPED BRIDGE GIRDER WITH EIGHT EMPTY DUCTS - WEST END VIEW

Stepped and tapered Styrofoam rods (101.6 mm or 4 inches in diameter) were inserted into

the ducts before grouting to form internal voids with sizes ranging from small to almost full

diameter voids. Figure 3 shows a Styrofoam rod being inserted into the top duct of the north

wall. A wire (3 mm or 1/8 inch in diameter) was bent to form a leg for the Styrofoam rod so that

the foam would be positioned on the roof of the duct, which simulates the real world grout

defects formed by air and water voids. Smaller defects were glued directly to the roof of the duct

since they were too thin for the wire leg. Figure 3 also shows the front view of a Styrofoam

defect inside a duct. The defect sizes are presented in Table 1 in terms of their circumferential

perimeter and duct depth lost. The defect designs are shown in Figure 4a for all four ducts in the

South web wall and Figure 4b for all four ducts in the North web wall. The actual percentage of

circumferential perimeter and diameter depth lost due to the defect are shown in the underlined

numbers placed directly above the defects in Figures 4a and 4b.

Defect ID

Circumferential

Lost (mm, in)

Depth Lost

(mm, in)

Percentage Lost in

Circumferential

Permineter (%)

Percentage

Lost in Depth

(%)

1 50.8, 2 6.35, 0.25 16 6

2 77.2, 3 13.6, 0.535 24 13

3 101.6, 4 23.4, 0.92 32 23

4 127, 5 34.8, 1.37 40 34

5 159.5, 6.28 50.8, 2 50 50

6 192.3, 7.57 66.8, 2.63 60 66

7 217.7, 8.57 78.2, 3.08 68 77

8 243.1, 9.57 87.9, 3.46 76 87

9 268.5, 10.57 95.2, 3.75 84 94

TABLE 1 – STYROFOAM DEFECT SIZES

Page 5: Impact-Echo Scanning for Grout Void Detection in Post

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FIGURE 3 – STYROFOAM SUPPORTED BY WIRE ROD (LEFT), THE FOAM ROD BEING INSERTED INTO THE DUCT TO FORM

VOIDS (CENTER) AND VIEW OF STYROFOAM DEFECT INSIDE A DUCT (RIGHT)

FIGURE 4a – DESIGN GROUT DEFECTS (STYROFOAM VOIDS) IN THE SOUTH WALL IN 101.6 MM (4 INCH) METAL

DUCTS FROM TOP DOWN

Page 6: Impact-Echo Scanning for Grout Void Detection in Post

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FIGURE 4b – DESIGN GROUT DEFECTS (STYROFOAM VOIDS) IN THE NORTH WALL IN 101.6 MM (4 INCH) METAL

DUCTS FROM TOP DOWN.

EXPERIMENTAL IE SCANNER RESULTS FROM THE MOCKUP GIRDER

Interpretation of Impact-Echo Data

Localization of grouting discontinuities through Impact-Echo in the mockup girder was based on an

analysis of variations in the Impact-Echo thickness echo depth/frequency. A direct echo from the void or

duct wall, measured as an Impact-Echo frequency corresponding to the depth of the discontinuity (given

by the formula in equation (1) above) has not yet been observed with the IE Scanner. However, as

previously found by others, the IE results indicate the presence of well-grouted, filled tendon ducts by a

nil to minor increase in apparent wall thickness over a grouted duct (typically on the order of 12.7 mm or

0.5 inches or less but larger in the research due to the 3 day age of the comparatively weak grout versus

the hardened, mature concrete). Grouting defects (Styrofoam voids) inside the ducts cause a more

significant increase of the apparent wall thickness in IE results as presented herein vs. well-grouted

ducts). This is in accordance with the interpretation of the Impact-Echo signal as a resonance effect,

rather than a reflection of a localized acoustical wave, i.e., the void may be simply thought of as a hole in

the web wall that due to decreased section stiffness causes a reduction in the resonant IE echo frequency

and a corresponding increase in thickness.

Discussion of Impact-Echo Results

The Impact-Echo tests were performed using a rolling IE Scanner at 1, 3 and 8 days of grout age after the

duct grouting process was completed by Restruction Corporation of Sedalia, Colorado. This paper

presents results from the South and North walls for testing conducted 3 days after the grouting of the

ducts was completed. Ultrasonic Pulse Velocity tests were performed on a sample of the grout placed on-

site in a 406.4 mm (16 in) long duct section. The grout velocity at 3 days old was 11,400 ft/sec,

indicative of solid grout but about 25 % slower than the velocity of the mature, hardened web wall

24” 60”

96” 132”

168” 204”

240”

32%,2340%,34

50%, 60%,66

68%,7784%,94

27.375” 63.375”

96” 132”

168” 204”

16%,624%,13

32%,2340%,34

50%,5076%,87

240”

22” 58”

96”

204” 240”

16%,6

16%,6

84%,9484%,94

Void

Page 7: Impact-Echo Scanning for Grout Void Detection in Post

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concrete. The results from the IE scanning of the South wall are presented in a thickness tomogram

fashion as shown in Figures 6 – 8 from the South wall and in a normalized thickness tomogram as shown

in Figures 9 - 11 from the North wall. Figures 6 – 11 all show the experimental results compared with the

actual defect designs of the ducts. The drawing of the actual defect design is placed above the

experimental results of the duct for comparison purposes.

Experimental Results from the South Wall

South Wall – Top Duct: The IE Scanner results from the South Wall with the actual defect design of the

top duct placed above the IE results of the top duct are shown in Figure 5. The results are interpreted to

indicate that the grout defect started to appear at a length of 1.93 m (76 in) and becomes clearly evident at

length of 2.92 m (115 in) from the west end of the duct. The location that the defect starts to appear

corresponds to void with 11% depth lost or 20% circumferential perimeter lost. The location that the

grout defect become more evident corresponds to void with 59% depth lost or 57% circumferential

contact diameter lost. The dominant frequency of the fully grouted duct is approximately 6.4 kHz,

resulting in an apparent Impact-Echo thickness of 28.37 mm (11.17 in.). The dominant frequency shifted

downward to approximately 5.37 kHz for an empty duct, which corresponds to an apparent Impact-Echo

thickness of 340 mm (13.4 in). This is a relatively large thickness shift of over 30% compared to the

nominal thickness of the wall. The interpretation of the Impact-Echo Scanner results, however, shows a

downshift in frequencies from lengths of 5.49 to 6.1 m (216 to 240 in), indicating voids at duct locations

where no discontinuities were intentionally placed. It is likely that grout did not flow into the higher east

duct end due to the big voids in front of it. Radiographic tests will be performed in the future to verify the

design versus actual conditions of the simulated defects.

FIGURE 5 – IE RESULTS FROM THE SOUTH WALL WITH ACTUAL DESIGN DEFECTS OF TOP DUCT

0 60 120 180 240 20 40 80 100 140 160 200 220

Length of Wall (inches)

0

4.8

4

3.2

2.4

1.6

0.8

Wall Height (ft)

72

144180

216

16%, 6%”

84%, 94% 76%, 87%

68%, 77%

Defect appears at length of 76 inches (from West end) – defect size of 20%, 11%

Defect can be identified clearly at length of 115 inches (from West end)

- Defect Size of 57%, 59%

West End East End

8.0

8.75

9.5

10.25

11.0

11.75

12.513.25

14.0

8.0

8.75

9.5

10.25

11.0

11.75

12.513.25

14.0

IES Thickness Echo Scale (inches)

Page 8: Impact-Echo Scanning for Grout Void Detection in Post

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South Wall – Second Duct from Top: Review of Figure 6 shows that there are three grout defect

zones. The first grout defect zone correlates with the end defect (13% depth lost or 24%

circumferential lost). The second defect zone shows minor grout problem from lengths of 0.91 –

1.67 m (36 – 66 in) from the west end of the duct. However, there is no actual defect placed in

this area. Radiography is required to confirm the realization of defect designs. The third defect

zone appears at a length of 3.35 m (132 in) which corresponds to defect of 9% in depth lost or

18.5% in circumferential lost. The most apparent grout defect appears at a length of 5.18 m (204

in) corresponding to the location of the largest Styrofoam in the duct (87% depth lost or 76%

circumferential perimeter lost). Similar to the results from the top duct, the interpretation of the

Impact-Echo Scanner results, however, shows a downshift in frequencies from lengths of 5.18 to

6.1 m (204 to 240 in), indicating major voids at duct locations where actual defect shape tapers

down toward the east end. It is likely that grout did not flow into the east end due to the large

voids in front of it.

South Wall – Third Duct from Top: Figure 7 shows three zones of grout defects. The first area

is located at the west end where Styrofoam Defect ID# 3 (see Table 1) is in place. However, the

IE results show that the duct is fully grouted between lengths of 0.45 – 2.13 m (18 – 84 in) from

the west end where there are actual Styrofoam defects placed in these locations. The grout

defect appears again between lengths of 2.13 – 3.2 m (84 – 126 in). The starting location of the

second defect zone corresponds to actual defect of 49% depth lost or 48% circumferential lost.

The end location of the defect zone corresponds to actual defect of 30% depth lost or 34%

circumferential lost. The interpretation of the Impact-Echo Scanner results, however, shows a

downshift in frequencies from lengths of 3.48 – 6.1 m (137 to 240 in), indicating minor to major

voids at duct locations where no actual Styrofoam defect in place. Radiography is required to

confirm the actual location of Styrofoam voids.

FIGURE 6 – IE RESULTS FROM THE SOUTH WALL WITH ACTUAL DESIGN DEFECTS OF SECOND DUCT

240

East End

16%, 6%

0 60 120 180 20 40 80 100 140 160 200 220

Length of Wall (inches)

0

4.8

4

3.2

2.4

1.6

0.8

Wall Height (ft)

West End

36”

240

204

132

24%, 13%

16%, 6%

76%, 87%

Grout defect appears at

length of 135 inches – Defect Size 24%,

13%

Worst defect area

Minor grout defect where

there is no Styrofoam

Grout defect appear at

Lengths of 6 – 30”

Page 9: Impact-Echo Scanning for Grout Void Detection in Post

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FIGURE 7 – IE RESULTS FROM THE SOUTH WALL WITH ACTUAL DESIGN DEFECTS OF THIRD DUCT

Experimental Results from the North Wall

North Wall – Top Duct: The IE results from the North Wall with the actual defect design of the

top duct placed above the IE results of the top duct are shown in Figure 8. Several pieces of

stepped Styrofoam were inserted inside this duct ranging from depth lost of 23% to 94% or

circumferential lost of 32% to 84%. All the results from four ducts from the North wall are

presented with normalized thickness tomogram. The results are interpreted to indicate that the

grout defect started to appear at the west end of the girder although there was not Styrofoam

inside the duct for the first 6.10 m (24 inches) from the west end. However, visual inspection

indicated there was honeycomb around the top duct of the north wall. Figure 8 showed that the

IE test was able to detect the grout defect of 23% depth lost or 32% circumferential lost. The

location that the grout defect is more evident corresponds to void with 50% depth and 50%

circumferential contact diameter lost.

0 60 120 180 240 20 40 80 100 140 160 200 220

0

4.8

4

3.2

2.4

1.6

0.8

Wall Height (ft)

29”

65”

101”

137”

16%, 6%2”

76%, 87% 16%, 6%

40%, 34% 32%, 23%

Length of Wall (inches) West End East End

Grout defect appears

from lengths of 84 - 126 inches

Page 10: Impact-Echo Scanning for Grout Void Detection in Post

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FIGURE 8 - IE RESULTS FROM THE NORTH WALL WITH ACTUAL DESIGN DEFECTS OF TOP DUCT AND THE

NORMALIZED THICKNESS SCALE

North Wall – Second Duct from Top: Several pieces of stepped Styrofoam were inserted inside

this duct ranging from depth lost of 6% to 87% or circumferential lost of 16% to 76%. Review

of Figure 9 shows that the grout defect started to appear at a length of 1.62 m (64 in) from the

west end of the girder. This length corresponds with location with voids of 13% lost in depth or

24% circumferential lost.

North Wall - Third Duct from Top: Review of Figure 10 shows that the grout defect started to

appear at a length of 2.59 m (102”) from the west end of the girder. This location corresponds to

void of 11% depth lost or 19% circumferential lost. In this case, the grout defect appear to be

apparent (full depth void) right at a length of 3.35 m (132 in) from the west end. This location

corresponds to void of 35% depth lost or 39% circumferential lost.

2460

96132

168204

240

32%, 23% 40% 34%

50%, 50% 60%, 66%

68%, 77% 84%, 94%

Length of Wall (inches)

48 96 144 240 16 32 64 80 112 128 160 224 0

West End East End

176 192 208

0

4.8

4

3.2

2.4

1.6

0.8

Wall Height (ft)

Grout defects start to appear at the west end

Grout defect becomes clear

Page 11: Impact-Echo Scanning for Grout Void Detection in Post

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27.37563.375

96132

168204

16%, 6% 24%, 13%

32%, 23% 40%, 34%

50%, 50% 76%, 87%

240

Length of Wall (inches)

48 96 144 240 16 32 64 80 112 128 160 224 0

West End East End

176 192 208

0

4.8

4

3.2

2.4

1.6

0.8

Wall Height (ft)

Grout defect appears at a length of 64 inches

FIGURE 9 – IE RESULTS FROM THE NORTH WALL WITH THE ACTUAL DESIGN DEFECTS OF THE SECOND DUCT

FIGURE 10 – IE RESULTS FROM THE NORTH WALL WITH THE ACTUAL DESIGN DEFECTS OF THE THIRD DUCT

CASE HISTORY

The results obtained from the research project were applied to a real world application. This

section presents an example case history using the Impact Echo Scanner to locate anomalies

inside post-tensioned bridge ducts inside the Orwell Bridge in UK (Figure 11). The testing was

conducted typically from inside each bridge from one side of each of the web walls with the

Impact Echo (IE) Scanning system. The tests were typically performed in vertical lines located

approximately every 2 meters (m) along a web wall and each vertical scan generally started from

22” 58”

96”

204” 240

16%, 6%

16%, 6%

84%, 94%

Length of Wall (inches)

48 96 144 240 16 32 64 80 112 128 160 224 0

West End East End

176 192 208

0

4.8

4

3.2

2.4

1.6

0.8

Wall Height (ft)

Grout defect appears at 102”

Page 12: Impact-Echo Scanning for Grout Void Detection in Post

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the bottom inside chamfer and ran to the top inside chamfer of the tested web walls for about 72

tests over 1.8 m of wall. A 2-D scan vertically up the wall from 0 to 2 m is shown in Figure 12.

The 2-D results shows a single time domain result and the corresponding linear frequency

displacement spectrum showing the resonant thickness echo peak along with the thickness vs.

distance plot that is the 2-D IES result. Potentially voided ducts are indicated by the greater

thicknesses in 2 locations (lower resonant frequency echo peaks due to voiding) in Figure 12.

The results from the tests are presented in a thickness tomogram fashion for each web wall for

each tested span with thicker areas indicative of potential void in the PT Ducts. An example test

result from one of the spans is presented in Figure 13. Review of Figure 13 shows

discontinuities or voids located at 20 m from Pier 2 and from the bottom of the wall (location

where the scan started) to a height of 0.6 m. The IE records indicated cracks/voids at depths of

12 – 15 cm from the test surface. In addition, the plot in Figure 13 also indicated a thicker area

(presented in black color) representing voids inside the duct(s) located at 42 m from Pier 2 and

from heights of 0.9 – 1.15 m. The color map in Figure 13 shows normalized thicknesses (the IE

thickness divided by the nominal thickness at the tested line) by color from 0.1 to 1.3.

FIGURE 11 – ORWELL BRIDGE

Page 13: Impact-Echo Scanning for Grout Void Detection in Post

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FIGURE 12 – VERTICAL IMPACT ECHO SCAN WITH 2 DUCT VOIDS OF 33 CM THICK WALL SECTION WITH 100 MM

DUCTS

Duct Voids

shown by shift in

thicknesses of 38

to 44 cm vs Wall

Echo of 33 cm

1.8 m at

end of

IE scan

O m at

start of

IE scan

Page 14: Impact-Echo Scanning for Grout Void Detection in Post

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FIGURE 13 – 3D NORMALIZED THICKNESS TOMOGRAM OF SPAN 2 OF NORTH BOX (GENERAL CONDITION)

SUMMARY

The results from the IE tests using portable rolling IE Scanner system show good agreement with the

actual defect design. In the IE testing by the authors to date, the clearest indication of the presence of

grouting defects is the apparent increase in the thickness due to a reduction in the IE resonant frequency

as a result of the decrease in stiffness associated with a defect. No direct “reflection” from the ducts with

grouting defects was observed in these experiments. This is because of larger wavelength generated by

the impactor inside the Impact-Echo Scanner. In this study, with the help of 3D visualization, the IE

scanning was able to identify voids as small as 9% depth lost or 20% circumferential diameter lost of a

101.6 mm or 4 inch diameter steel duct.

ACKNOWLEDGEMENTS The financial support from the NCHRP-IDEA program of the Transportation Research Board of the

National Academy of Sciences which made this research project possible is greatly appreciated by the

authors. The authors would also like to express their gratitude to Mr. Jim Fabinski of EnCon Bridge

Company (Denver, Colorado) for donating a full scale bridge girder for use of this research and the

assistance of Restruction Corporation in grouting the ducts.

Discontinuity at 20 m. from the ref.

(depth of 12 – 15 cm from the test surface)

0

0.4

0.8

1.2

1.6

22 32 42 52 622 12

2

Voids inside ductsPier 2 Pier 3

Height (meter)

Distance (meter)

Discontinuity at 20 m. from the ref.

(depth of 12 – 15 cm from the test surface)

0

0.4

0.8

1.2

1.6

22 32 42 52 622 12

2

Voids inside ductsPier 2 Pier 3

Height (meter)

Distance (meter)

Page 15: Impact-Echo Scanning for Grout Void Detection in Post

15

REFERENCES [1] Concrete Society Technical Report No. 47, “Durable Bonded Post-Tensioned Concrete Bridges”, Concrete

Society, 1996

[2] Woodward, R.J. and Williams, F.W., “Collapse of the Ynys-y-Gwas Bridge, West Glamorgan,”

Proceeding of The Institution of Civil Engineers, Part 1, Vol. 84, August 1988, pp. 635-669.

[3] Florida Department of Transportation (FDOT) Central Structures Office, “Test and Assessment of NDT Methods

for Post Tensioning Systems in Segmental Balanced Cantilever Concrete Bridges, Report, February 15, 2003.

[4] J. S. West, C. J. Larosche, B. D. Koester, J. E. Breen, and M. E. Kreger, “State-of-the-Art Report about

Durability of Post-tensioned Bridge Substructures”, Research Report 1405-1, Research Project 0-1405, Texas

Department of Transportation, October 1999.

[5] Sansalone, M. J. and Streett, W. B., Impact-Echo Nondestructive Evaluation of Concrete and Masonry. ISBN: 0-

9612610-6-4, Bullbrier Press, Ithaca, N. Y, 1997 339 pp.

[6] D. Sack and L.D. Olson, “Impact Echo Scanning of Concrete Slabs and Pipes”, International Conference on

Advances on Concrete Technology, Las Vegas, NV, June 1995

[7] ASTM C1383 "Test Method for Measurement P-Wave Speed and the Thickness of Concrete Plates Using the

Impact-Echo Method".